VW Caddy

The front-end of the VW Caddy after Project 3i-PRINT

A host of engineering and additive manufacturing companies have worked together to 3D print the front-end structure of a Volkswagen Caddy.

Altair, AirbusAPWORKS, csi entwicklungstechnik, EOS, GERG, and Heraeus were the players at the centre of the project as they aimed to bring new technology and classic engineering together. The project, they believe, demonstrates the vast potential of harnessing additive manufacturing as an industrial production tool.

Known as 3i-PRINT, the task took nine months to complete. Covering every step of the development process, from design to optimisation to manufacturing to post production, then result was a light and stable structure, able to be integrated functionally.

“We are proud to present the Caddy with an exemplary new additively manufactured front end structure,” said csi’s Stefan Herrmann, who was responsible for light weight design within the body. “The new structure and the contrast between old and new impressively demonstrates the potential that 3D printing and functional integration offer, particularly for the automotive industry.”

The 3i-PRINT project aimed to achieve as many advanced technical features as possible in as few components as possible. This included structural requirements that promised to ensure greater safety, performance and comfort. Additively manufactured components would include load-bearing structures that include active and passive cooling details which allow air to flow through to batteries and break system. Meanwhile, functions linked to heat management, passive safety, and fluids storage would also be integrated into the new front-end structure.

VW Caddy

With the targets set, csi’s experts designed the structure with Altair’s solutions, before developing and then building it. Then GERG connected the additively manufactured components and the creation of the final frame. APWORKS was responsible for the final dimensioning of the components, contributing its knowledge of print preparation and 3D printing of structural parts. The front-end structure was printed on an EOS M 400 platform in Scalmalloy, a high-strength aluminium alloy developed by APWORKS and supplied and qualified by Heraeus.

The project was instigated by csi, who called on a variety of leading players in their respective industries to explore how additive manufacturing can be leveraged to develop more efficient, functional automotive components.

“I would like to emphasise the agile, time-efficient route from the initial idea to the fully converted vehicle, which was completed within only nine months,” Herrmann added. “Each of the participating companies is a leader in its field. The outstanding collaboration and combined expertise has made the 3i-PRINT project a resounding success.”

Airbus APWORKS and Altair will be showcasing the front-end structure at this year's formnext powered by TCTevent in Frankfurt in Hall 3.1, booth F70.